How to print on hats: A practical small business guide

So you’ve decided to create hats for your business. These small business promotional items are perfect for spreading your brand message, and understanding how to screen print on hats will help you create professional results that last. From sports teams to corporate events, putting your custom logo on hats creates instant brand recognition and boosts visibility.

In this step-by-step guide, we dive into everything you need to know about how to print on hats, so you can create the perfect design and use the best printing method that aligns with your brand.

Key takeaways

• Screen printing on hats offers durable professional results for large orders.
• Multiple printing methods are available, each suited to different project needs and budgets.
• Professional printing services ensure consistent quality and save time.
• Proper design preparation helps guarantee best print results on hats.
• Material and color choices significantly impact print quality.

Already have your design?

Put it on custom hats with VistaPrint.

Start printing today!

Source: Modern logo design hat by Spoon Lancer via 99designs by Vista

Step-by-step guide to printing on hats

Let’s start with the practical steps to get your custom logo on hats, from design to final product.

Step 1: Choose your design

Before you start printing on hats, prepare your design carefully. Whether it’s your company logo, a graphic or a slogan, ensure it’s clean and scalable. Consider these key factors:

• Design complexity and size limitations
• Number of colors needed (more colors mean higher costs)
• Brand consistency requirements
• Target audience preferences

Tip

In need of inspiration for your design? Check out our hat design ideas.

Step 2: Prepare your artwork

For successful screen printing on hats, artwork preparation is crucial. Here’s what you need to do:

• Convert your design to vector format (.ai or .eps) for crisp edges.
• Ensure text is legible at the intended size.
• Consider color separations for screen printing.
• Create mockups on different hat colors.
• Prepare both full-size and scaled versions.

Step 3: Select hat styles and colors

Choose hats that work well with your printing method. Consider these factors:

• Material compatibility with your chosen printing method.
• Color contrast between hat and design.
• Hat style (structured, unstructured, snapback, fitted).
• Printing surface texture and seam placement.
• Budget and quantity requirements.

Step 4: Print your design

There are two main ways to printing your hat designs: working with a professional printing service or doing it yourself (DIY). Each has its own pros and cons. 

Work with a printing service

Professional services like VistaPrint make the printing process seriously easy. You simply upload your design and select your preferred hat style — they handle all the technical details. The process usually involves:

1. Submit your design.
2. Select your hat style and color options.
3. Review a digital proof before production begins.

Consider ordering a sample first to verify the print quality, color accuracy and design placement. While this option may cost more than DIY, it makes sure you have consistent quality across your entire order and eliminates the need to invest in equipment or master technical skills.

How to screen print hats

If you prefer the DIY approach, screen printing is a reliable method that creates sharp, durable designs. To get started, you’ll need:

• A screen printing press or DIY setup
• Appropriate inks for your hat material
• Blank hats for printing
• An exposure unit for creating screens
• Quality control tools (light box, measuring tools, color guides)

Screen printing works by using a mesh screen to transfer ink onto the fabric. While this method offers more creative control and can be cost-effective for larger runs, it requires a large investment in equipment and time to develop the necessary skills.

Source: Trendy WGMI hat design hat by Dudeowl 99designs by Vista

Now that you are familiar with the process of creating custom hats for your brand, let’s dive deeper into printing and design.

Choose the right printing method

So you’ve got your amazing hat design ready to go — exciting, right? But before you rush to get it printed, make sure you choose the right printing method for your project. 

Screen printing is generally the best all-around option for budget and quality, but it is not the only printing method.

Screen printing

Screen printing is a vibrant method of transferring designs onto fabric or paper by pushing ink through a stencil on a fine mesh screen. It’s like magic unfolding as each color layer is carefully added, resulting in bright, beautiful prints that feel handmade and full of personality. It works best for large runs and vibrant designs.

• Pros:
  • Excellent durability and wash resistance
  • Cost-effective for large quantities
  • Vibrant color reproduction
  • Works well on most hat materials
  • Professional finish
• Cons:
  • Higher setup costs
  • Minimum order requirements
  • Limited detail for intricate designs
  • Color matching can be challenging
• Best used when:
  • Ordering 50+ hats
  • Using bold simple designs
  • Needing long-lasting results

Embroidery

Embroidery transforms hats, totes, and t-shirts into premium, eye-catching products by stitching custom designs directly onto the fabric. It’s the perfect way to infuse personality, quality, and brand loyalty into each sale while delighting customers with long-lasting, handcrafted appeal! Because of the added textural details, this works best for text or simple designs.

• Pros:
  • Premium, textured appearance
  • Exceptional durability
  • Works on virtually any hat material
  • Professional look
  • Weather-resistant
• Cons:
  • Higher cost per unit
  • Limited color blending
  • May not suit complex designs
  • Slower production time
• Best used when:
  • Creating premium products
  • Working with simple logos
  • Needing weather-resistant results

Vinyl transfer

Vinyl transfer is a quick, budget-friendly way to press vibrant designs onto hats, totes, and t-shirts by applying heat and pressure to cut or printed vinyl. It’s a flexible method that lets you easily experiment with eye-catching, personalized graphics—perfect for wowing customers and scaling up your business! This approach is best for small runs or detailed multi-color designs.

• Pros:
  • No minimum order requirements
  • Excellent for multiple colors
  • Precise detail possible
  • Quick turnaround time
  • Good for prototypes
• Cons:
  • Less durable than other methods
  • Limited fabric compatibility
  • Can feel stiff or heavy
  • Higher cost for large quantities
• Best used when:
  • Ordering small quantities
  • Testing designs
  • Needing quick turnaround

Source: Travellers hat design by athenabelle via 99designs by Vista

Design tips for your custom logo on hats

A well-designed hat is a hat that people want to wear. Follow these design tips to create a professional, stylish design:

• Consider placement: Front panel placement works best for most designs, but explore side and back options too.
• Think about contrast: Light designs on dark hats need special consideration and often require an underbase.
• Keep it simple: Avoid too much detail that might get lost in the fabric.
• Size matters: Ensure your design is proportional to the hat’s printable area.

Source: Cool Money never sleeps hat design by diwaz via 99designs by Vista

Ready to rock your merch?

Learning how to print on hats opens up exciting possibilities for your brand merchandise. With the right printing method and design approach, you’ll create custom hats that look professional and last long. Your custom hat brand is just waiting to take off! Whether you’re launching a clothing line or creating team merch, now’s the perfect time to turn those designs into something real.

Ready to get started?

Print your hats with VistaPrint.

Let’s go!

FAQ

How do I pick the right hat style?

Think about who’ll be wearing your hats and where your design will go. If you’re planning a big, bold front design, snapbacks are your friend. Going for something more lowkey? Dad hats are perfect for smaller, centered logos. Just make sure your target audience also likes to wear that style!

What file format should I use for my design?

Vector files (like AI, EPS, or SVG) are your best bet since they stay sharp no matter how small (or big) you make them. If you’re working with regular images, no worries, just make sure they’re high-resolution (300 DPI or higher) PNGs or JPEGs with a transparent background.

Can I test things out with a sample first?

Yep! Most printing services are happy to run a sample for you first. 

How long until I get my hats?

Most companies need about 1-2 weeks, depending on how many hats you’re ordering and how you’re printing them. In a hurry? Rush options usually exist, but they’ll cost you extra. Pro tip: if you’re planning to order samples first (smart move!), factor that time in too. Learn more about designing hats with VistaPrint.